DBPL, 2x600MW units

Points discussed and suggestion

1. Furnace temperature measurement
Thermocouples for flame temperature measurement are provided at left and right hand sides of
boiler first pass at about 73m elevation. The length of thermocouple (projection inside the
furnace) is about one meter.
Thermocouples measure radiation temperature of flame. Since the length of probe is very small
compared to furnace width and flame flow pattern is not uniform across the plane of furnace at
that level, temperature value indicated by this thermocouple cannot be the correct one. Also the
thermocouple itself radiates.
So, temperature indicated cannot be the actual flame temperature.
The direction of rotation of fireball is anti-clockwise if we look down from top. Due to the
direction of rotation of fireball and its flow pattern, the flame at the exit of first pass will be
closure to LHS and at boiler horizontal pass flame passes closure to RHS. That is why steam
temperature pick-up in Divisional SH section is more at LHS and the temperature pick-up at
Reheater (located in horizontal pass) is more at RHS.
Flame flow pattern is the cause for higher metal temperature experienced by Reheater
assemblies at RHS and also for difference in flame temperature between LHS and RHS of furnace.
Flame temperature difference also depends on position of the flame. Temperature difference
will be more when bottom mills are in service or when burner tilt is down and it will be less when
top mills are in service or when burner tilt is upward. Temperature difference varies between
about 50°C to 100°C
In boiler back pass flue gas flow distribution is uniform across the plane and hence difference in
gas temperature between LHS and RHS will be very less (about10°C to 15°C). Also being fully
convective zone, gas temperature measured by thermocouple will be close to the actual value.
2. Flame in back pass
When access door at back pass top located close to LTSH terminal tube section was opened and
viewed inside, it was dark at LHS and at RHS in addition to darkness slight red colour was also
seen. This colour is due to radiation of the glowing flame.
3. Wind box to furnace DP and erosion of burner panel tubes
Burner panel tube erosion is mostly due to fly ash laden secondary air. Fly ash carry over from
APH is to be minimized by proper maintenance and seal setting.

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If coal nozzle tip is damaged, depending upon the extent of damage coal particles get diverted
from the stream and hit the burner panel tubes causing tube erosion.
The burner panel tubes not in alignment will erode fast preferentially. If windbox to furnace DP
is increased, air will be pushed away from wind box compartment.
The vertical gap between burner panel tubes and coal / air nozzles is to be set equal on either
sides during repair / replacement. Otherwise, velocity of air will increase where gap is less which
will fasten the rate of erosion.
4. Fuel air damper (FAD) position
Out of the total air quantity, primary air (PA) quantity should be just sufficient to dry / rise the
pulverized fuel (PF) temperature and to carry the PF into the furnace. Balance is the secondary
air (SA) which is sent through all windbox compartments. Airflow is regulated by Secondar Air
Dampers (SAD). SA includes Fuel air, Auxiliary air and End air.
Fuel Air Damper (FAD) is used mainly to push or pull the coal flame from coal nozzle tip.
Coal ignition depends mainly on the amount of Volatile Matter (VM) in coal. Coal having higher
VM will get ignited faster and so the coal flame needs to be pushed slightly away from nozzle tip
by opening FAD to avoid heating of nozzle tip. If VM is less, then ignition will be delayed and so
combustion air quantity is to be increased by reducing FAD opening and increasing auxiliary Air
Damper (AAD) opening.
As per SADC logic, FADs are set to open according to coal feeder speed. But in field based on the
quality of coal, FAD position is to be arrived for improved performance of boiler.
FAD opening with respect to coal quality (%VM) can be as below:

Sl No VM content FAD opening

1 < 17% 5% to 10%
2 17% to 20% 10% to 15%
3 > 20% 15% to 20%

This has been arrived based on experience with indigenous coal. This is a general guidelines which
needs to be experimented and arrived at during operation.
5. MTM limit
MTM limit is based on the oxidation limit of the material – it is specific temperature at which a
noticeable rate of oxidation occurs when the material begins to react significantly with oxygen in
the environment. Higher the temperature faster will be the oxidation. With scaling due to
oxidation the metal temperature increases faster leading to growth in scale thickness. If scale

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thickness increases, metal temperature will further increase leading to material degradation and
subsequently failure.
Different materials have different oxidation temperatures depending on the percentage of
alloying elements. Also there is slight variation in this temperature amongst the different codes
of construction.
Based on the experience with coal fired boilers since the environment is highly varying,
oxidation limit suggested for different material used is as below:

Carbon steel 430°C

Alloy steel SA213 T11 550°C
Alloy steel SA213 T22 580°C
Alloy steel SA213 T91 600°C
Stainless steel 700°C

6. Mill fineness:
Fineness of pulverized fuel for better combustion:

 retention in 50 mesh is less than 1.5% and

 70% (minimum) should passes through 200mesh.

Reactivity of coal, ash constituents, Mill outlet temperature / PF temperature, distribution of

combustion air in windbox compartments, excess air level, condition of coal nozzle and tips are
also some of the factors which decide combustion behaviour.
In general, if the ratio between fixed carbon and volatile matter (FC/VM) is close to 1.5 then
combustion will be good. If this ratio is still less combustion will be better.
7. Pad welding over boiler tubes
Pad welding over tubes is done to build up tube thickness or to take care of erosion. Pad welding
(though not recommended by IBR) is done when there is an urgency to bring back the unit. Tube
having pad welding are to be replaced during annual overhauls when sufficient time is available.
During pad welding the ID surface should not get affected by the heat of weld. So first few layers
are to be welded by filler wire followed by lower size weld electrode.
If electrodes are used right from first pass, then tube ID gets affected and the surface will not be
smooth because of weld heat and that surface will become sites for deposit leading to corrosion
related problems; build-up done at slanted tubes will be more vulnerable for corrosion.

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The photos below show hydrogen damage to furnace bottom S panel tube at pad welding
location.

ID surface of pad welding – rough surface,

S panel tube with pad welding
the sites for deposit leads to corrosion
related failure

Window opening at pad welding location –

hydrogen damage failure

Weld reinforcement during welding

The sketches below show the extent of weld reinforcement (height) and the angle of
reinforcement (Fig1 and Fig.2) in weld. The angle as shown has to be >100° with smooth
transition between parent metal and weld.
Excess reinforcement as shown in Fig.3 and Fig.4 is not advisable and will lead to failure.

Fig.1 Fig.2 Shallow Obtuse

angle > 100 

R = max 3 mm

R - weld reinforcement

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 Fig. 3 Fig.4
High level of SC
Obtuse angle > 90 Acute angle
< 90

8. Soot blower drain temperature:

Once wall blower is charged, thermal drain valve will open to clear the condensate from wall
blower piping. Thermal drain valve will close once the blowing steam temperature reaches a set
value which is minimum 25°C more than the saturation temperature corresponding to the wall
blower set pressure. The blowing steam set pressure at wall blower inlet is 10 kg/cm 2
9. APH soot blowing pressure
APH soot blowing pressure can be set at about 10 to 11kg/cm2.
10. HRH temperature low:
Boiler is designed to fire 405 tph of coal for TMCR generation of 600MW. At present, the quantity
of Coal being fired for full load generation is around 350 tph only.
In RH maximum portion of heat transfer is by convection. Convective heat transfer is proportional
to velocity of gas. If gas volume generated by coal combustion is less, gas velocity will get reduced
and hence convective heat pick-up also.
At present, the quality of coal being fired is better than design coal and reactivity of coal is also
better. Coal with better reactivity will burn faster and combustion gets completed well below
goose neck portion. Since gas temperature at RH inlet is less (comparatively) and also gas velocity,
convective heat pick-up in RH will be less and accordingly HRH steam temperature also will be
less.
HRH steam temperature can be improved if we delay combustion by adjusting airflow through
windbox compartments (SADCs).
This was attempted in unit 1 on 22-01-2025 and improvement in RH temperature was observed
to the tune of 10°C. Details given in the last page.

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11. Soot deposit over Divisional SH is at one side (LHS) only
This is because of direction of rotation of fireball which is anti-clockwise looking down from top.
At Divisional SH section the fire ball moves from LHS to RHS. So, soot deposit will be at left side
surface of Divisional SH.
12. Wall blower and LRSB operation practice
Wall blower and LRSBs are used to clean the heat transfer surfaces (tubes). If tubes are fouled or
soot formation is there, then heat transfer from flame / flue gas to tube and to medium (water /
steam) will reduce and gas temperature will be high at boiler exit sections. Spray flow in SH and
RH will also increase gradually if tube surfaces are not clean. If there is no appreciable increase
in sprays and boiler exit gas temperature between subsequent blowing, then frequency of
blowing can be reduced, say once in a shift to once in two shifts or once in a day.
Effectiveness of blowing in each tier / row of wall blowers can be observed during each blowing
in-terms of SH & RH spray quantity, boiler exit gas temperature and accordingly blowing
frequency can be decided. Normally, soot deposit on furnace wall below windbox will be less, so
frequency of steam blowing at this section (bottom most row of blowers) can be reduced.
From the discussion at site, it is understood that

 LRSB nos. 105 and 106 are operated once in a day; this can be continued since these blowers
are located below goose neck where there is possibility for soot deposit.
 LRSBs 123 &124 and 129 &130 located above rear arch section are operated to clear
accumulated ash which otherwise causes flame failure trip (as informed at site).

Ash accumulation over rear arch occurs when the flue gas velocity is less which happens during
part load operation or while firing better coal. When boiler is operating at full load with design
coal, frequency of operation of these blowers can be reduced.
On 22-01-2025 when trials were carried out to improve HRH steam temperature, boiler exit gas
temperature was also recorded. Refer the Table given at the end;
On 22-01-2025, wall blowing was completed at @1200hrs. During the trial it was observed that
boiler exit gas temperature was almost the same through-out the shift. Increase in boiler exit gas
temperature by about 5/6°C was because of increase in gas temperature at RH section.
13. Ash deposit over rear arch section
Ash deposit over rear arch section is mainly due to low gas velocity. As it has been practiced, the
LRSBs located above rear arch are to be operated to clear the ash and to avoid possible flame
failure trip. Ash deposit over rear arch will not pose operational problems.

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14. Reason for overheating of tubes
Boiler tubes size (thickness and diameter) is designed based on working pressure and desired
pressure drop in each assembly. Tube material is selected based on maximum metal temperature
anticipated during service. Tube is a conduit wherein flow and as well as heat transfer take place.
The flame / gas temperature is transferred to tube material though radiation / convection, and
tube gets cooled by the medium (water / steam) flowing through tube.
Tube will get overheated if

1) it is not getting cooled sufficiently by the medium flowing inside - reasons for insufficient
cooling is partial / less flow caused by
 choking inside tube by foreign material,
 deposit / scales
 flow stratification (design deviation) etc.
2) it is exposed to higher flame temperature (more than the oxidizing limit) than design –
caused by over-firing, flame laning or flame impingement
3) improper selection of material – use of lower grade material for the service requirement.

Overheating reduces the strength of material and material will not be able to withstand service
condition and will fail finally depending upon the extent of overheating and exposure time.
15. Momentary increase in metal temperature
Metal temperature rise beyond the allowable limit will increase the stress on material. Time / life
before failure depends on level and duration of metal temperature rise and the no. of times the
temperature rise occurs.
Momentary rise for few seconds just above the allowable limit is not a serious issue but extent
of temperature and duration at higher temperature matter.
Failure due to raise in metal temperature is purely material property and the service condition.
It is very difficult to comment about value of safe temperature, duration allowed at higher
temperature and no. of times.
Microstructural analysis reveals condition of material w r to the service and remaining service
life.
16. Temperature difference between steam and metal (dT)
In boiler tubes where the maximum thickness is about 10mm, this dT will be of the order of 15°C
to 20°C. Deposit inside the tubes will increase the dT to even about 100°C.
(Assumption - steam temperature is the same as metal temperature at ID and metal temperature
referred here is the temperature measured on OD of the tube / header).

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Deposit and scale inside will further increase dT. Increase in dT will induce thermal strain leading
to failure especially in case of high thickness components.
Thermal insulation over high temperature and high thickness components like final SH, RH
headers and pipes will minimize the dT across the thickness.
In drum the dT allowed between top (steam side) and bottom (water side) surfaces is about 50°C.
17. Oxide layer at different locations:
Oxide layer thickness in tubes depends on the metal temperature; higher the metal temperature
and time of exposure will increase the oxide layer thickness. Once sufficient scale thickness is
formed then metal temperature will raise faster because of poor conductivity of scale; once the
metal temperature increases growth of scale / scale thickness also will be faster.
In subcritical boiler where MS and HRH steam temperatures are 540°C the failures or problems
related to oxide scale (scale formation and its growth and finally failure due to metal temperature
raise) is very less.
Even in fresh tubes / assemblies that are manufactured / heat treated during manufacturing,
scale thickness observed is to the tune of 100 to 150 microns.
In general tubes with oxide thickness up to a level of 250 to300 microns do not require
replacement, but need close observation w r to scale growth.
18. Forced cooling of boiler
Forced cooling is normally done to attend BTL and to bring back the unit within shortest possible
time. Many Power Stations do fast cooling by operating ID & FD fans.
During forced cooling, temperature difference (dT) across the thickness of tubes and headers is
the main factor to be monitored. If dT is more, then the material will be subjected to undue
strain. For tubes this dT will be very less to cause undue strain to the material. But for high
thickness components dT will be more which might induce strain resulting in problems related to
fatigue during cycling.
During forced cooling dT across the thickness is to be monitored for high thickness components.
Cooling by water is to be avoided.
19. Windbox bottom end air damper (AA) position
Bottom end air damper (AA) can be kept at 50% opening all the time. Damper regulation is by
lever which is manually operated from outside.
20. Furnace exit flue gas temperature at Divisional SH area
This is discussed in first point that is about furnace flame temperature

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21. O2 level monitoring and probe location
The predicted Excess Air level for complete combustion is 20% and the corresponding oxygen
level in flue gas is 3.6%. Amount of excess air required for complete combustion will vary based
on quality of coal.
21a. How to get the correct amount of Excess air?
Maintain a constant coal flow.
Optimize the mill air flow.
Keep secondary air (SA) flow (and hence the total airflow) minimum based on operation
experience. Increase the SA in steps of 10 tph and monitor drum pressure. The drum
pressure will increase with excess air. The correct excess air level would be corresponding to
the value at which drum pressure starts dropping. Assumption - coal quality is consistent.
If coal is not homogeneous and quality is varying frequently, getting the optimum excess air is
difficult and it might be required to operate the boiler with higher excess air level in order to
ensure combustion.
21b. Probe location:
Grid measurement of oxygen is to be carried out and O2 probe for monitoring excess air level
is to be positioned at the location where we get percentage oxygen close to the average
value from grid measurement.
22. Furnace temperature mapping
Furnace temperature is to be measured with separate instruments at 60%, 80% and 100% loads
at different mill combinations. This will give details with respect to flame temperature pattern
across the boiler at different elevations.
The temperature values need not be the same at similar operating conditions, it varies with coal
quality, excess air level, windbox damper positions, burner tilt etc.,
23. APH outlet Flue gas temperature variation between left and right
Reasons:
Gas flow variation: Normally gas flow through each APH is almost equal. If damper at one of the
APH outlet is partially closed, slightly more gas flow will be diverted towards the other APH which
will increase gas outlet temperature for the same amount of PA and SA flows.
Air bypass into flue gas stream: If APH seals gap is more, more air will pass into flue gas stream
because of pressure differential. Depending upon the quantity of air passing into gas stream, gas
temperature will be reduced.

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Trials carried out in unit 1 on 22-01-2025: boiler parameters during trials are given in table 1:
Major parameters: Load: 600MW, Coal flow: 350tph, Total airflow: 2000tph, MS flow:1840tph,
Mills in service: B to F, burner tilt:18°
Boiler 1 was operating at full load 600MW with 350 tph of coal flow.
In the trial, combustion within furnace was delayed by reducing AAD opening and at the same
time OFA damper opening was increased to complete combustion. This has caused increase in
gas temperature at RH inlet and hence HRH steam temperature.
Table 1A gives SADC openings during trials and corresponding important parameters of RH & SH.
T0 is the initial operating condition and T1,..T8 are the trial numbers.
Initially OFA lower and OFA upper damper opening were respectively at 0% and 100%. Windbox
to furnace DP was maintained at 70mmWC, FAD opening was 15%. AAD opening was 67%.
During the trials, FAD opening was maintained at 15%, windbox to furnace DP was increased from
70 mmWC to 90 mmWC and OFA dampers were opened to 100% in steps.
Observation:

 About 10°C increase in HRH steam temperature

 RH metal temperature was within limit
 SH spray was normal.
 Minor reduction in NoX level
 Unburnt in bottom ash – 1.36%, unburnt in fly ash 0.3%
There are scope for further improvement
Table 1A . Main parameters during trials:
Parameter unit T0 T1 T2 T3 T4 T5 T6 T7 T8
Windbox to furnace
mmwc 70 70 75 80 80 80 80 80 90
DP
OFA Lower opening % 100 50 50 50 75 75 100 100 100
OFA Upper opening % 0 50 50 50 50 75 75 100 100
FAD opening % 15 15 15 15 15 15 15 15 15
AAD opening % 67 60 52 49 43 42 42 42 37
MS Temp Lt °C 538 542 540 541 541 538 541 538 538
MS Temp Rt °C 538 542 541 540 541 537 542 539 538
HRH Temp Lt °C 523 526 525 529 532 534 532 533 536
HRH Temp Rt °C 521 524 523 527 530 531 530 531 534
SH Spray Lt tph 22 41.2 32 48.9 60.8 64 53.5 48 43.5
SH Spray Rt tph 0 19.2 0 7 26.8 19 12.6 15 9.1
SH spray - total tph 22 60.4 32 55.9 87.6 83 66.1 63 52.6

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Table !: Boiler parameters recorded during trials carried out to improve RH steam temperature

Parameter Unit 1 2 3 4 5 6 7 8 9
Parameter change at hrs 1500 1515 1545 1608 1630 1650 1710 1733 1755
Time of reading hrs 1503 1537 1606 1626 1646 1706 1727 1746 1833
Load MW 604 63 604 606 600 601 600 603 602
Coal flow tph 345 347 345 342 345 345 347 346 347
Airflow tph 2042 2013 2030 2038 2002 2014 2000 2024 2008
MS flow tph 1851 1848 1848 1851 1823 1826 1823 1840 1844
Oxygen Lt % 3.0 2.7 2.9 2.7 2.7 2.9 2.7 2.8 3.0
Oxygen Rt % 3.0 2.7 2.9 2.8 2.7 3.0 2.8 2.9 2.8
MS Temp Lt °C 538 542 540 541 541 538 541 538 538
MS Temp Rt °C 538 542 541 540 541 537 542 539 538
HRH Temp Lt °C 523 526 525 529 532 534 532 533 536
HRH Temp Rt °C 521 524 523 527 530 531 530 531 534
LTSH out temp Lt °C 400 403 403 405 409 409 409 408 408
LTSH out temp Rt °C 406 409 407 406 410 409 407 407 406
SH Spray Lt tph 22 41.2 32 48.9 60.8 64 53.5 48 43.5
SH Spray Rt tph 0 19.2 0 7 26.8 19 12.6 15 9.1
SH spray total tph 22 60.4 32 55.9 87.6 83 66.1 63 52.6
Divn SH in temp Lt °C 393 390 390 394 388 391 392 389 393
Divn SH in temp Rt °C 407 404 406 405 401 402 402 403 404
Divn SH out temp Lt °C 473 468 473 467 464 464 466 464 466
Divn SH out temp Rt °C 470 467 473 469 467 470 469 468 471
FG temp APH in Lt °C 336 336 337 338 338 338 339 339 341
FG temp APH in Rt °C 336 337 338 339 339 338 339 339 342
FG temp APH out Lt °C 133 124 134 134 135 135 134 134 133
FG temp APH out Rt °C 124 125 125 125 125 125 125 124 124
Windbox press mmwc 70 70 75 80 80 80 80 80 90
OFA Lower opening % 100 50 50 50 75 75 100 100 100
OFA Upper opening % 0 50 50 50 50 75 75 100 100
FAD opening % 15 15 15 15 15 15 15 15 15
AAD opening % 67 60 52 49 43 42 42 42 37
Burner tilt Deg 18 18 18 18 18 18 18 18 18
RH MTM C No. 51 °C 573 575 570 570 572 569 568 571 572
C No. 53 °C 550 549 554 560 557 554 562 556 571
C No. 67 °C 553 553 553 556 557 554 558 557 565
NoX mg/Nm3 266 269 253 248 268 273 240 243 244

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